Wear-resistant member having a hard composite comprising hard constituents held in an infiltrant matrix

ABSTRACT

A tough wear-resistant hard member that includes a hard composite member and a support that has a surface area adjacent to the hard composite member wherein the hard composite member is affixed to the support over at least a portion of the adjacent surface area of the support. The hard composite member includes a plurality of discrete hard constituents distributed in the hard composite member wherein each one of the discrete hard constituents is of a size so as to have a surface area between about 0.001 square inches and about 16 square inches. The hard composite member further contains a matrix powder that includes particles wherein substantially all of the hard particles have a size smaller than the size of the hard constituents. The hard composite member further includes an infiltrant alloy having a melting point between about 500 degrees Centigrade and about 1400 degrees Centigrade wherein the infiltrant alloy is infiltrated under heat into a mixture of the discrete hard constituents and the matrix powder so as to not effectively degrade the hard constituents upon infiltration, whereby the hard constituents and the matrix powder and the infiltrant alloy are bonded together to form the hard composite member. The support is made of a material that is bondable with the infiltrant alloy whereby the infiltrant alloy forms a joint at the joinder of the support and the hard composite member.

BACKGROUND OF THE INVENTION

[0001] The invention pertains to a wear-resistant member. In particular,the invention concerns a wear member that includes a hard compositemember that is securely affixed to at least a portion of a supportmember. The hard composite comprises a plurality of hard componentswithin a mold wherein an infiltrant alloy that has been infiltrated intothe mass of the hard components.

[0002] In the past, the temperature at which the infiltrant alloy hasbeen infiltrated into the mass of hard components has been high enoughso that the infiltrant alloy had the potential to degrade the hardcomponents upon contact therewith. Thus, there has been a desire to usean infiltrant alloy that has a melting point sufficiently low so as tominimize degradation of the hard components upon contact therewith.

[0003] There has also always remained the desire to render themanufacturing process for hard composite members less difficult. Itwould thus be desirable to use an infiltrant alloy that would ease themanufacturing process for the hard composite.

[0004] One example of a hard composite wherein degradation of the hardcomponent was a concern was shown in U.S. Pat. No. 3,149,411 to Smileyet al. In the Smiley et al. patent there was an attempt to minimize thedegradation of the cemented carbides by using an alloy that had amelting point between about 1750 degrees Fahrenheit (about 954 degreesCentigrade) and about 3000 degrees Fahrenheit (about 1649 degreesCentigrade). According to the Smiley et al. patent, the alloy also hadto contain a metal from Group VIII, Series 4 of the Periodic Table(i.e., iron, cobalt or nickel) and minor amounts of chromium and boron.In the examples (see Cols. 7-8) of the Smiley et al. patent, the typicalinfiltration temperature ranged between about 2250 degrees Fahrenheit(1232 degrees Centigrade) and about 2600 degrees Fahrenheit (1427degrees Centigrade).

[0005] Another example of a hard composite that had a matrix infiltratedbetween the interstices of a mass of the hard particles was shown inU.S. Pat. No. 3,175,260 to Bridwell et al. In the Bridwell et al.patent, particles of cemented tungsten carbide or tungsten carbide alloywere heated and the molten matrix metal poured into the mold containingthe hard particles. The Bridwell et al. patent mentioned that themelting point of the matrix metal ranged between about 1550 degreesFahrenheit (843 degrees Centigrade) and 2400 degrees Fahrenheit (1316degrees Centigrade). The infiltration temperature ranged between about1750 degrees Fahrenheit (945 degrees Centigrade) and about 2500 degreesFahrenheit (1371 degrees Centigrade).

[0006] U.S. Pat. No. 5,589,268 to Kelley et al. (U.S. Pat. No. 5,733,649to Kelley et al. was a divisional thereof) pertained to a composite thatcomprised at least one discrete hard element held by a matrix powderwherein an infiltrant alloy had been infiltrated into the hardcomponents. One suggested infiltrant alloy was a copper-nickel-zincalloy identified as MACROFIL 65 wherein literature from Belmont Metals,Inc. showed that the melting point was 1100 degrees Centigrade. Anothersuggested infiltrant alloy was acopper-manganese-nickel-zinc-boron-silicon alloy identified as MACROFIL53. According to the Kelley et al. patent, the MACROFIL 53 was usuallyinfiltrated at about 2200 degrees Fahrenheit (1204 degrees Centigrade).U.S. Pat. No. 5,733,664 to Kelley et al. was a continuation-in-part tothe '268 Kelley et al. patent. The '664 Kelley et al. patent alsodisclosed the MACROFIL 53 alloy and the MACROFIL 65 alloy.

[0007] Since it is desirable to avoid the degradation of the hardcomponents of a hard composite due to contact with the infiltrant alloy,it would be advantageous to provide a hard composite that utilizes amatrix material that does not degrade (or minimizes the degradation) ofthe hard components upon contact therewith during the infiltrationprocess.

[0008] It is typical that for some applications, the hard compositeattaches to a support member to form a wear member. The purpose of thehard composite is to provide wear resistance to the combination of thehard composite and the support member. The support member is intended toprovide toughness to the wear member. In these cases, it would beadvantageous for the infiltrant alloy and the support member to exhibitcompatible properties so as to form a good bond between the hardcomposite and the support. In this application, it would also beadvantageous to maintain the wear resistance properties, as well as thetoughness properties, of the hard composite.

SUMMARY OF THE INVENTION

[0009] In one form thereof the invention is a tough wear-resistant hardmember that includes a hard composite member and a support that has asurface area adjacent to the hard composite member wherein the hardcomposite member is affixed to the support over at least a portion ofthe adjacent surface area of the support. The hard composite memberincludes a plurality of discrete hard constituents distributed in thehard composite member wherein each one of the discrete hard constituentsis of a size so as to have a surface area between about 0.001 squareinches and about 16 square inches. The hard composite member furthercontains a matrix powder that includes particles wherein substantiallyall of the hard particles have a size smaller than the size of the hardconstituents. The hard composite member further includes an infiltrantalloy having a melting point between about 500 degrees Centigrade andabout 1400 degrees Centigrade wherein the infiltrant alloy isinfiltrated under heat into a mixture of the discrete hard constituentsand the matrix powder so as to not effectively degrade the hardconstituents upon infiltration, whereby the hard constituents and thematrix powder and the infiltrant alloy are bonded together to form thehard composite member. The support is made of a material that isbondable with the infiltrant alloy whereby the infiltrant alloy forms ajoint at the joinder of the support and the hard composite member.

[0010] In another form thereof the invention is A tough wear-resistanthard member that comprises a support having a surface area and a hardcomposite member that is affixed to the support over at least a portionof the surface area of the support. The hard composite member comprisesa plurality of discrete hard constituents distributed in the hardcomposite member wherein each one of the discrete hard constituents isof a size so as to have a surface area between about 0.001 square inchesand about 16 square inches. The discrete hard constituents comprise oneor more of: sintered cemented tungsten carbide wherein a binder includesone or more of cobalt, nickel, iron and molybdenum, coated sinteredcemented tungsten carbide wherein a binder includes one or more ofcobalt, nickel, iron and molybdenum, and the coating comprises one ormore of nickel, cobalt, iron and molybdenum, one or more of thecarbides, nitrides, and borides of one or more of titanium, niobium,tantalum, hafnium, and zirconium, tungsten carbide, one or more of thecoated carbides, coated nitrides, and coated borides of one or more oftitanium, niobium, tantalum, hafnium, and zirconium wherein the coatingcomprises one or more of nickel, cobalt, iron and molybdenum; coatedtungsten carbide wherein the coating comprises one or more of nickel,cobalt, iron and molybdenum, coated silicon carbide wherein the coatingcomprises one or more of nickel, cobalt, iron and molybdenum, and coatedsilicon nitride wherein the coating comprises one or more of nickel,cobalt, iron and molybdenum; coated boron carbide. The hard compositemember further comprises a matrix powder comprising hard particleswherein substantially all of the hard particles of the matrix powderhave a smaller size than the hard constituents. The hard compositemember further comprises an infiltrant alloy having a melting pointbetween about 500 degrees Centigrade and about 1400 degrees Centigradewherein the infiltrant alloy is infiltrated under heat into a mixture ofthe discrete hard constituents and the matrix powder so as to noteffectively degrade the hard constituents upon infiltration, whereby thehard constituents and the matrix powder and the infiltrant alloy arebonded together to form the hard composite member. The support is madeof a material that is bondable with the infiltrant alloy whereby theinfiltrant alloy forms a joint at the joinder of the support and thehard composite member.

[0011] In yet another form thereof, the invention is a toughwear-resistant hard member that comprises a hard composite member and asupport having a surface area adjacent to the hard composite member. Thehard composite member is affixed to the support over at least a portionof the adjacent surface area of the support. The hard composite membercomprises a plurality of discrete hard constituents distributed in thehard composite member, each one of the discrete hard constituents is ofa size so as to have a surface area between about 0.001 square inchesand about 16 square inches. The hard composite member further comprisesa matrix powder comprising hard particles wherein substantially all ofthe hard particles have a size smaller than the size of the hardconstituents. The hard composite member further comprises an infiltrantalloy having a melting point between about 500 degrees Centigrade andabout 1400 degrees Centigrade wherein the infiltrant alloy isinfiltrated under heat into a mixture of the discrete hard constituentsand the matrix powder so as to not effectively degrade the hardconstituents upon infiltration, whereby the hard constituents and thematrix powder and the infiltrant alloy are bonded together to form thehard composite member. The support is made of a material that isbondable with the infiltrant alloy whereby the infiltrant alloy forms ajoint at the interface of the support and the hard composite member.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The following is a brief description of the drawings that form apert of this patent application wherein:

[0013]FIG. 1 is an isometric view of a tough wear-resistant member inthe form of a plate wherein the tough wear-resistant member comprises ahard composite that provides wear resistance and contains hardconstituents held in an infiltrant matrix and a support (e.g., steel)that provide toughness;

[0014]FIG. 2 is a schematic view of a hard member that comprises a hardcomposite and a support wherein the matrix holds the hard constituentsto form the hard composite and there is a bond between the hardcomposite and the support;

[0015]FIG. 3 is a schematic view of the components of the hard member ofFIG. 2 in a mold prior to the infiltration of the matrix materialthrough the mass of hard constituents wherein the infiltrant matrixmaterial is on top of the mass of hard constituents, and the mass ofhard constituents is positioned on a support;

[0016]FIG. 4 is an isometric view of a specific embodiment of a hardmember that comprises a hard composite and a support wherein a pluralityof sintered cemented carbide compacts that comprise a part of the hardcomposite have at least a portion thereof that projects from the surfaceof the hard composite;

[0017]FIG. 5 is a cross-sectional view of a wear resistant tube whereinthe interior layer of the pipe comprises a support and the exteriorlayer of the pipe comprises a hard composite so that the exteriorsurface possesses wear-resistant properties;

[0018]FIG. 6 is a cross-sectional view of a wear-resistant tube whereinthe exterior layer of the tube comprises a support and the interiorlayer of the tube comprises a hard composite so that the interior layerpossesses wear-resistant properties; and

[0019]FIG. 7 is an isometric view of a center feed disk for an impellerrock crusher wherein the disk that presents an inner portion thatpresents a hard composite with a circular wear surface and a cylindricalwear surface and an outer portion that presents a circular ordoughnut-like wear surface wherein the support member presents anon-planar interface (or surface) for joinder with the hard composite;

[0020]FIG. 7A is a cross-sectional view of the center feed disk of FIG.7 illustrating the non-planer interface between the hard composite andthe support;

[0021]FIG. 8 is a cross-sectional view of a tough wear resistant memberwherein the interface between the hard composite and the supportpresents a roughened surface; and

[0022]FIG. 9 is a cross-sectional view of a tough wear resistant memberwherein the support contains holes therein with a portion of the hardcomposite contained within the holes.

DETAILED DESCRIPTION OF THE INVENTION

[0023] Referring to the drawings, one specific embodiment of the toughwear-resistant hard member generally designated as 20 is shown inFIG. 1. Tough wear-resistant member 20 is in the form of a plate;however, one must appreciate that the tough wear-resistant member cantake on any one of a number of different shapes or geometries toaccommodate different applications. In this regard, some of the laterembodiments illustrated herein present different geometries.

[0024] The tough wear-resistant hard member 20 comprises a support 22and a hard composite 24. The hard composite 24 is affixed to the support22. The hard composite 24 provides the wear resistant properties and thesupport 22 provides the toughness properties.

[0025]FIG. 2 illustrates the tough wear-resistant member 20 of FIG. 1 inschematic fashion so as to show a cross section of the hard member 20.FIG. 3 is a schematic view that shows the general relative positioningof the components in the mold prior to the formation of the tough wearresistant member 20 of the embodiment of FIG. 1.

[0026] The support 22 may be made from any one of many materials thatpossess properties so as to provide toughness properties (as well assupport) for the tough wear-resistant member 20. These materials include(without limitation) ferrous alloys and non-ferrous alloys, as well asother supports that may require a wear-resistant surface. Specificexemplary materials for the support comprise various steels such as, forexample, AISI 4140 steel and AISI 316 stainless steel. The nominalcomposition (in weight percent) for the AISI 4140 steel is: 0.38-0.43%carbon, 0.75-1.00% manganese, 0.035% phosphorous, 0.040% sulfur,0.15-0.35% silicon, 0.80-1.10% chromium, 0.15-0.25% molybdenum and thebalance iron. The nominal composition (in weight percent) for 316stainless steel is: maximum carbon 0.08%, maximum manganese 2.00%,maximum phosphorous 0.030%, maximum silicon 0.030%, 10.00-16.00% nickel,16.00-18.00% chromium, 2.00-3.00% molybdenum, and the balance iron. Thesupport could also comprise a casting having hard particles therein.Although this aspect will be further discussed hereinafter, the supportshould also possess properties so that it is bondable with theinfiltrant alloy whereby there is a secure bond between the support 22and the hard composite 24.

[0027] In the specific embodiments of FIGS. 1 through 3, the hardcomposite 24 comprises a plurality of discrete hard constituents(described hereinafter) wherein these hard constituents are held withina matrix designated by bracket 30. The matrix comprises a mass of matrixpowder that comprises different kinds of hard particles and/or powders,and an infiltrant alloy 31 (FIG. 3) that has been infiltrated into themass of the matrix powder and the hard constituents under the influenceof heat and sometimes under additional environmental influences such as,for example, in a pressure or in a vacuum. Furthermore, the infiltrantalloy may be infiltrated into the mass of hard constituents and matrixpowder under various atmospheres (e.g., argon, helium, hydrogen, andnitrogen).

[0028] In the specific embodiment of FIGS. 1 through 3, the hardconstituents comprise sintered cemented carbide compacts 34 that areshown in schematic in FIGS. 2 and 3 as a triangle-shaped member. Inregard to the sintered cemented carbide compact 34, this hardconstituent presents a specific pre-determined shape. This shape canvary depending upon the specific application for the toughwear-resistant hard member. Powder metallurgical techniques allow forthe shape of the compact 34 to take on any one of a number of shapes orgeometries. As an alternative, the hard compact 34 could crushed toobtain hard constituents. Applicant contemplates that the compact 34 isof a size so as to have a surface area that ranges between about 0.001square inches (0.006 square centimeters) and about 16 square inches (103square centimeters). Applicant also contemplates that the compact may beof a size that ranges between about 0.005 square inches (0.03 squarecentimeters) and about 5 square inches (33 centimeters). Applicantfurther contemplates that the compact may be of a size that rangesbetween about 0.0005 square inches (0.003 square centimeters) and about0.5 square inches (0.003 centimeters). The specific embodiment of FIGS.1 through 3 shows that each one of the sintered cemented carbidecompacts 34 is selectively positioned within the matrix of the hardcomposite 24. As FIG. 3 shows schematically, one generally accomplishessuch orientation by selectively positioning the sintered cementedcarbide compacts 34 in the mold prior to infiltration. Applicantcontemplates that the compacts 34 may cover between about 0.5 percent toabout 90 percent of the surface area of the wear-resistant hard member.

[0029] In the specific embodiment of FIGS. 1 through 3 (and as shown inschematic by FIGS. 2 and 3), the location of the sintered cementedcarbide compacts 34 is in a region near the surface of the hardcomposite 24. As shown in schematic in FIGS. 2 and 3, sintered cementedcarbide compacts 34 are also located in a region near the interfacebetween the hard composite 24 and the support 22 whereby these compactsare on the surface of the support 22. Some of the sintered cementedcarbide compacts 34 are also located above the sintered cemented carbidecompacts 34 on the support 22. In this particular embodiment, thesintered cemented carbide compacts 34 are flush with the surface of thehard composite 24 so that they do not project therefrom. Applicant doesnot intend to restrict the invention to the specific positioning of thehard constituents in the hard composite. For example, the hardconstituents may be uniformly (or non-uniformly or randomly) distributedthroughout the volume of the hard composite.

[0030] One composition of the sintered cemented carbide compact 34 iscobalt cemented tungsten carbide wherein the cobalt ranges between about0.2 weight percent and about 6 weight percent of the cobalt cementedtungsten carbide compact and tungsten carbide is the balance of thecomposition. Another composition for the sintered cemented carbidecompact 34 is cobalt cemented tungsten carbide wherein the cobalt rangesbetween about 6 weight percent and about 30 weight percent of the cobaltcemented tungsten carbide compact and tungsten carbide is the balance ofthe composition. In still another composition, the sintered cementedcarbide compact may comprise cobalt (10 weight percent cobalt) cementedtungsten carbide.

[0031] By mentioning the above specific hard constituent, applicant doesnot intend the limit the scope of the invention to this specific hardconstituent. Applicant contemplates that other materials would besuitable for use as the hard constituents in the hard composite. In thisregard, the following materials would appear to be suitable for use ashard constituents in the hard composite: sintered cemented tungstencarbide wherein a binder includes one or more of cobalt, nickel, ironand molybdenum; coated sintered cemented tungsten, carbide wherein abinder includes one or more of cobalt, nickel, iron and molybdenum, andthe coating comprises one or more of nickel, cobalt, iron andmolybdenum; one or more of the carbides, nitrides, and borides of one ormore of titanium, niobium, tantalum, hafnium, and zirconium; one or moreof the coated carbides, coated nitrides, and coated borides of one ormore of titanium, niobium, tantalum, hafnium, and zirconium wherein thecoating comprises one or more of nickel, cobalt, iron and molybdenum;chromium carbides; coated chromium carbides; coated silicon carbidewherein the coating comprises one or more of nickel, cobalt, iron andmolybdenum; and coated silicon nitride wherein the coating comprises oneor more of nickel, cobalt, iron, copper, molybdenum or any othersuitable metal; and coated boron carbide wherein the coating comprisesone or more of nickel, cobalt, iron, copper, molybdenum, and any othersuitable metal.

[0032] The matrix powder comprises a crushed cemented carbide particle36 that is shown in schematic in FIGS. 2 and 3 as an oval-shaped member,and a crushed cast carbide particle 38 that is shown in schematic inFIGS. 2 and 3 as a circular-shaped member.

[0033] Referring to the components of the matrix powder, the crushedcemented carbide particles 36 may be present in a size range for thesecrushed cemented carbide particles equal to −325+200 mesh. Another sizerange for these crushed cemented carbide particles is −80+325 mesh. Thestandard to determine the particle size is by using sieve size analysisand the Fisher sub-sieve size analyzer for −325 mesh particles. Onecomposition for the crushed cemented carbide particles is cobaltcemented tungsten carbide wherein the cobalt ranges between about 6weight percent and about 30 weight percent of the cobalt cementedtungsten carbide material and tungsten carbide is the balance of thematerial. Another preferred composition for crushed cemented carbideparticles is cobalt cemented tungsten carbide wherein the cobalt rangesbetween about 0.2 weight percent and about 6 weight percent of thecobalt cemented tungsten carbide material and tungsten carbide is thebalance of the material.

[0034] By mentioning specific compositions, applicant does not intendthe limit the scope of the invention to these specific cementedcarbides. Applicant contemplates that other cemented carbides (e.g.,chromium carbide) would be suitable for use as the crushed cementedtungsten carbide particles in the hard composite. In this regard, thecarbides could be different from tungsten carbide (e.g., titaniumcarbide and chromium carbide) and the binder could be different fromcobalt (e.g., nickel). Applicant further contemplates that the crushedcemented carbide particles may vary in composition throughout aparticular hard composite depending upon the specific application.Applicant also contemplates that certain hard materials other thancemented carbides may be suitable to form these particles.

[0035] In regard to the crushed cast carbide particles 38, one sizerange for these particles is −325 mesh. Another size range for theseparticles is −80 mesh. One composition for these particles is casttungsten carbide. Applicant contemplates that the crushed cast carbideparticles may vary in composition throughout a particular hard compositedepending upon the specific application. Applicant further contemplatesthat other cast carbides or hard materials are suitable for use in placeor along with the crushed cast carbide particles 38.

[0036] The matrix powder may further include in addition to crushedcemented carbide particles and/or crushed cast carbide particles, anyone or more of the following: crushed carbide particles (e.g., crushedtungsten carbide particles that have a size of −80+325 mesh), steelparticles that have an exemplary size of −325 mesh, carbonyl ironparticles that have an exemplary size of −325 mesh, cemented carbidepowder, and coated (e.g., nickel coating) cemented carbide particles,and nickel-coated tungsten carbide particles (−80+325 mesh).

[0037] As show in FIG. 3, the crushed cemented carbide particles and thecast carbide particles are generally positioned throughout the volume ofthe mold.

[0038] As discussed above, it is desirable that the infiltrant alloy 31has a melting point that is low enough so as to not degrade the hardconstituents upon contact therewith during the infiltration process.Along this line, the infiltrant alloy has a melting point that rangesbetween about 500 degrees Centigrade and about 1400 degrees Centigrade.Applicant contemplates that the infiltrant alloys may have a meltingpoint that ranges between about 600 degrees Centigrade and about 800degrees Centigrade. Applicant further contemplates that the infiltrantalloys may have a melting point that ranges between about 690 degreesCentigrade and about 770 degrees Centigrade. Applicant still furthercontemplates that the infiltrant alloys may have a melting point belowabout 700 degrees Centigrade. Exemplary general types of infiltrantalloys include copper-based alloys such as, for example, copper-silveralloys, copper-zinc alloys, copper-nickel alloys, copper-tin alloys, andnickel-based alloys including nickel-copper-manganese alloys. Exemplaryinfiltrant alloys are set forth in Table 1 herein below. TABLE 1Compositions of Infiltrant Alloys in Weight Percent Liquidus Solidus(Flow Alloy/ (Melting Point) Composition Cu Ni Zn Mn Ag Sn Point)(° C.)° C. A-1 53 15  8 24 — — 1150  202 45 — 35 — 20 — 710 815 255 40 — 33 —25 2 690 780 559 42  2 — — 56 — 770 895 700 20 — 10 — 70 — 690 740

[0039] By mentioning specific infiltrant alloys in Table 1, applicantdoes not intend to limit the scope of the invention to infiltrant alloyswith these specific compositions and/or properties.

[0040] Referring to FIG. 4 there is shown a tough wear-resistant member50 that has a hard composite 52 affixed to a support 54. The hardcomposite 52 contains a plurality of sintered cemented carbide compacts56 that project from one surface thereof. In this embodiment, thesupport typically is made from 4140 steel. The hard composite body 52typically comprises sintered cemented carbide compacts 56 that typicallyhave a composition of 10 weight percent cobalt and the balance tungstencarbide. The matrix powder typically includes tungsten carbide, chromiumcarbide, as well as cobalt and nickel in the form of a binder alloy forthe carbides and/or a coating on the carbides. One typical infiltrantalloy has a composition (weight percent) ofcopper(53%)-nickel(15%)-manganese(24%)-zinc (8%) and a melting pointequal to about 1150 degrees Centigrade.

[0041] Referring to FIG. 5 there is shown a tough wear-resistant member60 that has a cylindrical hard composite 62 affixed to a cylindricalsupport 64. In this embodiment, the support 64 typically is made fromeither 316 stainless steel or 4140 steel. The hard composite body 62typically comprises hard constituents that comprise one or more sinteredcarbides wherein these carbides include tungsten, titanium, niobium,tantalum, hafnium, chromium and zirconium. The matrix powder typicallycomprises one or more sintered carbides, crushed sintered carbides, castcarbide, crushed carbides, tungsten carbide powders and chromium carbidepowders. The infiltrant alloy has a composition (weight percent) ofcopper(53%)-nickel(15%)-manganese(24%)-zinc(8%) and a melting pointequal to about 1150 degrees Centigrade.

[0042] Referring to FIG. 6 there is shown a tough wear-resistant member70 that has a cylindrical hard composite 72 affixed to a cylindricalsupport 74. In this embodiment, the support typically is made from 4140steel or 316 stainless steel. The hard composite body 62 typicallycomprises hard constituents that comprise one or more sintered carbideswherein these carbides include tungsten, titanium, niobium, tantalum,hafnium, chromium and zirconium. The matrix powder typically comprisesone or more sintered carbides, crushed sintered carbides, cast carbide,crushed carbides, tungsten carbide powders and chromium carbide powders.The infiltrant alloy has a composition of copper(53%)-nickel(15%)-manganese(24%)-zinc(8%) and a melting point equal to about 1150degrees Centigrade.

[0043] Referring to FIGS. 7 and 7A, there is shown a toughwear-resistant member generally designated as 80 that has a hardcomposite 82 affixed to a support 84. Member 80 is a center feed diskfor an impeller rock crusher. In this embodiment, the support 84typically is made steel (e.g., 4140 steel) or white iron. The support 84has a cylindrical base 86 with an inner cylindrical projection 88. Ascan be seen from the cross-sectional view of FIG. 7A, there is anon-planer interface between the support 84 and the hard composite 82.As also can be seen from FIGS. 7 and 7A, the hard composite 82 presentsdifferent wear surfaces 90 and 92 and cylindrical wear surface 93wherein wear surface 90 is an inner circular surface and wear surface 92is an outer circular or doughnut-like surface.

[0044] The hard composite body 82 typically comprises hard constituentsthat typically comprise cemented carbides, silicon carbides, boroncarbide, aluminum oxide, zirconia and other suitable hard materials. Thematrix powder typically comprises one or more of crushed tungstencarbide, crushed cemented tungsten carbide, crushed cast tungstencarbide, iron powder, tungsten carbide powder (the tungsten carbide madeby a thermit process or from co-carburized tungsten carbide) and/orchromium carbide powder. The infiltrant alloy has a composition ofcopper(53%)-nickel(15%)-manganese(24%)-zinc(8%) and a melting pointequal to about 1150 degrees Centigrade.

[0045] Referring to FIG. 8, there is shown a tough wear-resistant membergenerally designated as 96. Member 96 has a support 98 that presents aroughened surface 100. Wear-resistant member 96 further includes a hardcomposite 102. The interface between the hard composite 102 and thesupport 98 is roughened as shown by FIG. 8.

[0046] Referring to FIG. 9, there is shown still another embodiment of atough wear-resistant member generally designated as 106. Wear-resistantmember 106 comprises a support 108 that contains a hole or bore 110 thatpasses all the way through the thickness of the support 108. Support 108further contains a closed-end bore 112 of one depth and anotherclosed-end bore of another depth 114. Bore 112 has a greater depth thendoes bore 114.

[0047] Wear-resistant member 106 also includes a hard composite 116.Hard composite 106 extends into the volumes of the bores (110, 112, 114)as is shown in the cross-sectional view of FIG. 9. The interface betweenthe hard composite and the support is generally planar, except for thepresence of the openings to the bores.

[0048] Examples of specific matrix powders (Mixtures Nos. 1 through 20)are set forth in Tables 2 through 6 hereinafter. TABLE 2 Components ofthe Matrix Powder Mixtures Nos. 1 through 4 (Weight Percent) ConstituentMixture Mixture Mixture Mixture (particle size) No. 1 No. 2 No. 3 No. 4Crushed tungsten 67 wt. % 67 wt. % 0 wt. % 0 wt. % carbide (−80 +325mesh) Crushed tungsten 0 wt. % 15.5 wt. % 0 wt. % 0 wt. % carbide (−325mesh) Crushed cast 31 wt. % 15.5 wt. % 0 wt. % 0 wt. % tungsten carbide(−325 mesh) 4600 steel (−325 1 wt. % 0 wt. % 0 wt. % 0 wt. % mesh)Carbonyl iron 1 wt. % 0 wt. % 0 wt. % 0 wt. % (−325 mesh) Nickel (−325 0wt. % 2 wt. % 0 wt. % 0 wt. % mesh) Crushed cobalt 0 wt. % 0 wt. % 100wt. % (10 wt. Percent) cemented tungsten carbide (−140 +325 mesh)Crushed nickel 0 wt. % 0 wt. % 100 wt. % (10 wt. Percent) cementedtungsten carbide (−140 +325 mesh)

[0049] TABLE 3 Components of the Matrix Powder Mixtures Nos. 5 through 8(Weight Percent) Constituent Mixture Mixture Mixture Mixture (particlesize) No. 5 No. 6 No. 7 No. 8 Crushed tungsten 63.65 wt. % 63.65 wt. % 0wt. % 0 wt. % carbide (−80 +325 mesh) Crushed tungsten 0 wt. % 14.725wt. % 0 wt. % 0 wt. % carbide (−325 mesh) Crushed cast 29.45 wt. %14.725 wt. % 0 wt. % 0 wt. % tungsten carbide (−325 mesh) 4600 steel(−325 .95 wt. % 0 wt. % 0 wt. % 0 wt. % mesh) Carbonyl iron .95 wt. % 0wt. % 0 wt. % 0 wt. % (−325 mesh) Nickel (−325 0 wt. % 1.9 wt. % 0 wt. %0 wt. % mesh) Crushed cobalt 0 wt. % 0 wt. % 95 wt. % (10 wt. Percent)cemented tungsten carbide (−140 +325 mesh) Crushed nickel 0 wt. % 0 wt.% 95 wt. % (10 wt. Percent) cemented tungsten carbide (−140 +325 mesh)Chromium 5 wt. % 5 wt. % 5 wt. % 5 wt. % carbide (−45 mesh)

[0050] TABLE 4 Components of the Matrix Powder Mixtures Nos. 9 through12 (Weight Percent) Constituent Mixture Mixture Mixture Mixture(particle size) No. 9 No. 10 No. 11 No. 12 Crushed tungsten 53.6 wt. %53.6 wt. % 0 wt. % 0 wt. % carbide (−80 +325 mesh) Crushed tungsten 0wt. % 12.4 wt. % 0 wt. % 0 wt. % carbide (−325 mesh) Crushed cast 24.8wt. % 12.4 wt. % 0 wt. % 0 wt. % tungsten carbide (−325 mesh) 4600 steel(−325 .8 wt. % 0 wt. % 0 wt. % 0 wt. % mesh) Carbonyl iron (−325 .8 wt.% 0 wt. % 0 wt. % 0 wt. % mesh) Nickel (−325 0 wt. % 1.6 wt. % 0 wt. % 0wt. % mesh) Crushed cobalt 0 wt. % 0 wt. % 80 wt. % (10 wt. Percent)cemented tungsten carbide (−140 +325 mesh) Crushed nickel 0 wt. % 0 wt.% 0 wt. % 80 wt. % (10 wt. Percent) cemented tungsten carbide (−140 +325mesh) Nickel Coated 20 wt. % 20 wt. % 20 wt. % 20 wt. % Tungsten CarbidePowder (−325 mesh)

[0051] TABLE 5 Components of Matrix Powder Mixtures 13 through 16(Weight Percent) Constituent Mixture Mixture Mixture Mixture (particlesize) No. 13 No. 14 No. 15 No. 16 Crushed tungsten 60.3 wt. % 60.3 wt. %0 wt. % 0 wt. % carbide (−80 +325 mesh) Crushed tungsten 0 wt. % 13.95wt. % 0 wt. % 0 wt. % carbide (−325 mesh) Crushed cast 27.9 wt. % 13.95wt. % 0 wt. % 0 wt. % tungsten carbide (−325 mesh) 4600 steel (−325 .9wt. % 0 wt. % 0 wt. % 0 wt. % mesh) Carbonyl iron (−325 .9 wt. % 0 wt. %0 wt. % 0 wt. % mesh) Nickel (−325 0 wt. % 1.8 wt. % 0 wt. % 0 wt. %mesh) Crushed cobalt 0 wt. % 0 wt. % 90 wt. % (10 wt. Percent) cementedtungsten carbide (−140 +325 mesh) Crushed nickel 0 wt. % 0 wt. % 0 wt. %90 wt. % (10 wt. Percent) cemented tungsten carbide (−140 +325 mesh)Crushed nickel 10 wt. % 10 wt. % 10 wt. % 10 wt. % (15 wt %) cementedchromium carbide(Ni- Cr₃C₂) (−140 +325 mesh)

[0052] TABLE 6 Components of Matrix Powder Mixtures 17 through 20 (inWeight Percent) Constituent Mixture Mixture Mixture Mixture (particlesize) No. 17 No. 18 No. 19 No. 20 Crushed tungsten 56.95 wt. % 56.95 wt.% 0 wt. % 0 wt. % carbide (−80 +325 mesh) Crushed tungsten 0 wt. %13.175 wt. % 0 wt. % 0 wt. % carbide (−325 mesh) Crushed cast 26.35 wt.% 13.175 wt. % 0 wt. % 0 wt. % tungsten carbide (−325 mesh) 4600 steel(−325 .85 wt. % 0 wt. % 0 wt. % 0 wt. % mesh) Carbonyl iron .85 wt. % 0wt. % 0 wt. % 0 wt. % (−325 mesh) Nickel (−325 0 wt. % 1.7 wt. % 0 wt. %0 wt. % mesh) Crushed cobalt 0 wt. % 0 wt. % 85 wt. % (10 wt. Percent)cemented tungsten carbide (−140 +325 mesh) Crushed nickel 0 wt. % 0 wt.% 85 wt. % (10 wt. Percent) cemented tungsten carbide (−140 +325 mesh)Nickel-coated 15 wt. % 15 wt. % 15 wt. % 15 wt. % tungsten carbide (−325mesh)

[0053] In regard to some specific examples, a tough wear-resistantmember was made wherein there was a support and a hard composite. Thehard composite comprised hard constituents that comprised sinteredcobalt (10 weight percent cobalt) cemented tungsten carbide compacts andthe matrix powder comprised Mixture No. 1 in Table 1 and the infiltrantalloy comprised (in weight percent) a Cu(53%)-Ni(15%)-Zn(8%)-Mn(24%)alloy described above. The matrix powder comprised 40 weight percent andthe infiltrant alloy comprised 60 weight percent of the combination ofthe matrix powder and the infiltrant alloy. Depending upon the specificapplication, the cemented tungsten carbide compacts were present in aspecified amount between about 1 weight percent and about 95 weightpercent with the balance of the hard composite comprising the matrixpowder and the infiltrant alloy. In the alternative and depending uponthe specific application, the cemented tungsten carbide compacts werepresent in a specified amount between about 1 weight percent and about90 percent of the surface area of the hard composite.

[0054] Another tough wear-resistant member was made wherein there was asupport and a hard composite. The hard composite comprised hardconstituents. The hard constituent comprised a sintered cobalt (6 weightpercent cobalt) cemented tungsten carbide compact. The matrix powdercomprised Mixture No. 2. The infiltrant alloy comprised in weightpercent) a Cu(53%)-Ni(15%)-Zn(8%)-Mn(24%). The matrix powder comprised45 weight percent and the infiltrant alloy comprised 55 weight percentof the combination of the matrix powder and the infiltrant alloy.Depending upon the specific application, the cemented tungsten carbidecompacts were present in a specified amount between about 1 weightpercent and about 95 weight percent with the balance of the hardcomposite comprising the matrix powder and the infiltrant alloy. In thealternative and depending upon the specific application, the cementedtungsten carbide compacts were present in a specified amount betweenabout 1 weight percent and about 90 percent of the surface area of thehard composite.

[0055] Still another tough wear-resistant member was made wherein therewas a support and a hard composite. The hard composite comprised hardconstituents wherein the hard constituent comprised sintered cobalt (6weight percent cobalt) cemented tungsten carbide cylindrical compacts.The matrix powder was Mixture No. 3 as set forth in Table 1. Theinfiltrant alloy comprised (in weight percent) aCu(53%)-Ni(15%)-Zn(8%)-Mn(24%). The matrix powder comprised 40 weightpercent and the infiltrant alloy comprised 60 weight percent of thecombination of the matrix powder and the infiltrant alloy. Dependingupon the specific application, the cemented tungsten carbide compactswere present in a specified amount between about 1 weight percent andabout 95 weight percent with the balance of the hard compositecomprising the matrix powder and the infiltrant alloy. In thealternative and depending upon the specific application, the cementedtungsten carbide compacts were present in a specified amount betweenabout 1 weight percent and about 90 percent of the surface area of thehard composite.

[0056] Another tough wear-resistant member was made wherein there was asupport and a hard composite. The hard composite comprised hardconstituents comprised of nickel-coated sintered cobalt (10 weightpercent cobalt) cemented tungsten carbide compacts. The matrix powdercomprised Mixture No. 4 from Table 1. The infiltrant alloy comprised (inweight percent) a Cu(53%)-Ni(15%)-Zn (8%)-Mn(24%). The matrix powdercomprised 45 weight percent and the infiltrant alloy comprised 55 weightpercent of the combination of the matrix powder and the infiltrantalloy. Depending upon the specific application, the cemented tungstencarbide compacts were present in a specified amount between about 1weight percent and about 95 weight percent with the balance of the hardcomposite comprising the matrix powder and the infiltrant alloy. In thealternative and depending upon the specific application, the cementedtungsten carbide compacts were present in a specified amount betweenabout 1 weight percent and about 90 percent of the surface area of thehard composite.

[0057] All patents, patent applications, articles and other documentsidentified herein are hereby incorporated by reference herein. Otherembodiments of the invention may be apparent to those skilled in the artfrom a consideration of the specification or the practice of theinvention disclosed herein. It is intended that the specification andany examples set forth herein be considered as illustrative only, withthe true spirit and scope of the invention being indicated by thefollowing claims.

What is claimed is:
 1. A tough wear-resistant hard member comprising: ahard composite member; a support having a surface area adjacent to thehard composite member; the hard composite member affixed to the supportover at least a portion of the adjacent surface area of the support; thehard composite member comprising a plurality of discrete hardconstituents distributed in the hard composite member, each one of thediscrete hard constituents is of a size so as to have a surface areabetween about 0.001 square inches and about 16 square inches; the hardcomposite member further comprising a matrix powder comprising hardparticles wherein substantially all of the hard particles have a sizesmaller than the size of the hard constituents; the hard compositemember further comprising an infiltrant alloy having a melting pointbetween about 500 degrees Centigrade and about 1400 degrees Centigrade,and the infiltrant alloy being infiltrated under heat into a mixture ofthe discrete hard constituents and the matrix powder so as to noteffectively degrade the hard constituents upon infiltration, whereby thehard constituents and the matrix powder and the infiltrant alloy arebonded together to form the hard composite member; and the support beingmade of a material that is bondable with the infiltrant alloy wherebythe infiltrant alloy forms a joint at the joinder of the support and thehard composite member.
 2. The tough wear-resistant member of claim 1wherein the matrix powder comprises one or more of the following:crushed cemented carbide particles, crushed cast carbide particles,crushed carbide particles, and cemented carbide powder, steel particles,carbonyl iron particles, and coated carbide particles.
 3. The toughwear-resistant member of claim 1 wherein the matrix powder comprisesbetween about 50 weight percent to about 70 weight percent crushedtungsten carbide having a particle size of −80+325 mesh, between about24 weight percent and about 32 weight percent crushed cast tungstencarbide having a particle size of −325 mesh, between about 0.8 weightpercent and about 1.2 weight percent steel particles having a particlesize of −325 mesh, between about 0.8 and 1.2 weight percent carbonyliron particles having a particle size of −325 mesh, between 0 weightpercent and about 7 weight percent chromium carbide particles having aparticle size of −45 mesh, between 0 and about 25 weight percentnickel-coated tungsten carbide particles having a particle size of −325mesh, and between 0 weight percent and about 15 weight percent crushedcemented chromium carbide-nickel particles having a particle size of−140+325 mesh.
 4. The tough wear-resistant member of claim 1 wherein thematrix powder comprises between about 65 weight percent and about 69weight percent crushed tungsten carbide particles having a particle sizeof −325 mesh, between about 29 weight percent and about 33 weightpercent crushed cast tungsten carbide particles having a particle sizeof −325 mesh, between about 0.9 weight percent and about 1.1 steelparticles having a particle size of −325 mesh, and between about 0.9weight percent and about 1.1 weight percent carbonyl iron particleshaving a particle size of −325 mesh.
 5. The tough wear-resistant memberof claim 1 wherein the matrix powder comprises between about 61 weightpercent and about 66 weight percent crushed tungsten carbide particleshaving a particle size of −325 mesh, between about 27 weight percent andabout 31 weight percent crushed cast tungsten carbide particles having aparticle size of −325 mesh, between about 0.8 weight percent and about1.0 steel particles having a particle size of −325 mesh, between about0.8 weight percent and about 1.0 weight percent carbonyl iron particleshaving a particle size of −325 mesh, and be between about 65 weightpercent and about 69 weight percent crushed tungsten carbide particleshaving a particle size of −325 mesh, between about 29 weight percent andabout 33 weight percent crushed cast tungsten carbide particles having aparticle size of −325 mesh, between about 0.9 weight percent and about1.1 steel particles having a particle size of −325 mesh, and betweenabout 0.9 weight percent and about 1.1 weight percent carbonyl ironparticles having a particle size of −325 mesh and between about 4 weightpercent and about 6 weight percent chromium carbide particles having aparticle size of −45 mesh.
 6. The tough wear-resistant member of claim 1wherein the matrix powder comprises between about 51 weight percent andabout 56 weight percent crushed tungsten carbide particles having aparticle size of −325 mesh, between about 22 weight percent and about 37weight percent crushed cast tungsten carbide particles having a particlesize of −325 mesh, between about 0.7 weight percent and about 0.9 steelparticles having a particle size of −325 mesh, between about 0.7 weightpercent and about 0.9 weight percent carbonyl iron particles having aparticle size of −325 mesh, and between about 15 weight percent andabout 25 weight percent nickel-coated tungsten carbide particles havinga particle size of −325 mesh.
 7. The tough wear-resistant member ofclaim 1 wherein the matrix powder comprises between about 58 weightpercent and about 63 weight percent crushed tungsten carbide particleshaving a particle size of −325 mesh, between about 25 weight percent andabout 29 weight percent crushed cast tungsten carbide particles having aparticle size of −325 mesh, between about 0.8 weight percent and about1.0 steel particles having a particle size of −325 mesh, between about0.8 weight percent and about 1.0 weight percent carbonyl iron particleshaving a particle size of −325 mesh., and between about 8 weight percentand about 12 weight percent crushed cemented chromium carbide-nickelparticles of a particle size −140+325 mesh.
 8. The tough wear-resistantmember of claim 1 wherein the matrix powder comprises between about 65weight percent and about 69 weight percent crushed tungsten carbideparticles of a particle size of −80+325 mesh, between about 12 weightpercent and about 17 weight percent crushed tungsten carbide particleshaving a particle size of −325 mesh, between about 12 weight percent andabout 17 weight percent crushed cast tungsten carbide particles having aparticle size of −325 mesh, and between about 1.5 weight percent andabout 2.5 weight percent nickel particles having a particle size of −325mesh.
 9. The tough wear-resistant member of claim 1 wherein the matrixpowder comprises between about 61 weight percent and about 66 weightpercent crushed tungsten carbide particles of a particle size of −80+325mesh, between about 11 weight percent and about 16 weight percentcrushed tungsten carbide particles having a particle size of −325 mesh,between about 11 weight percent and about 16 weight percent crushed casttungsten carbide particles having a particle size of −325 mesh, andbetween about 1.5 weight percent and about 2.5 weight percent nickelparticles having a particle size of −325 mesh, and between about 4weight percent and about 6 weight percent chromium carbide particleshaving a particle size of −45 mesh.
 10. The tough wear-resistant memberof claim 1 wherein the matrix powder comprises between about 51 weightpercent and about 56 weight percent crushed tungsten carbide particlesof a particle size of −80+325 mesh, between about 10 weight percent andabout 15 weight percent crushed tungsten carbide particles having aparticle size of −325 mesh, between about 10 weight percent and about 15weight percent crushed cast tungsten carbide particles having a particlesize of −325 mesh, and between about 1.3 weight percent and about 1.9weight percent nickel particles having a particle size of −325 mesh, andbetween about 15 weight percent and about 25 weight percentnickel-coated tungsten carbide particles having a particle size of −325mesh.
 11. The tough wear-resistant member of claim 1 wherein the matrixpowder comprises between about 58 weight percent and about 63 weightpercent crushed tungsten carbide particles of a particle size of −80+325mesh, between about 12 weight percent and about 17 weight percentcrushed tungsten carbide particles having a particle size of −325 mesh,between about 12 weight percent and about 17 weight percent crushed casttungsten carbide particles having a particle size of −325 mesh, andbetween about 1.5 weight percent and about 2.5 weight percent nickelparticles having a particle size of −325 mesh, and between about 7weight percent and about 13 weight percent crushed cemented chromiumcarbide-nickel particles having a particle size of −140+325 mesh. 12.The tough wear-resistant member of claim 1 wherein the matrix powdercomprises between about 80 weight percent and about 100 weight percentcrushed cobalt cemented tungsten carbide particles having a particlesize of −140+325 mesh, and between 0 weight percent and about 10 weightpercent chromium carbide particles having a particle size of −45 mesh,between 0 weight percent and about 25 weight percent nickel-coatedtungsten carbide particles having a particle size of −325 mesh, andbetween 0 weight percent and about 15 weight percent crushed cementedchromium carbide-nickel particles having a particle size of −140+325mesh.
 13. The tough wear-resistant member of claim 1 wherein the matrixpowder comprises about 100 weight percent crushed cobalt cementedtungsten carbide particles having a particle size of −140+325 mesh. 14.The tough wear-resistant member of claim 1 wherein the matrix powdercomprises about 95 weight percent crushed cobalt cemented tungstencarbide particles having a particle size of −140+325 mesh, and about 5weight percent chromium carbide particles having a particle size of −45mesh.
 15. The tough wear-resistant member of claim 1 wherein the matrixpowder comprises about 80 weight percent crushed cobalt cementedtungsten carbide particles having a particle size of −140+325 mesh, andabout 20 weight percent nickel-coated tungsten carbide particles havinga particle size of −325 mesh.
 16. The tough wear-resistant member ofclaim 1 wherein the matrix powder comprises about 90 weight percentcrushed cobalt cemented tungsten carbide particles having a particlesize of −140+325 mesh, and about 10 weight percent crushed cementedchromium carbide-nickel particles having a particle size of −140+325mesh.
 17. The tough wear-resistant member of claim 1 wherein the matrixpowder comprises between about 80 weight percent and about crushednickel cemented tungsten carbide particles having a particle size of−325 mesh, and between 0 weight percent and about 10 weight percentchromium carbide particles having a particle size of −45 mesh, between 0weight percent and about 25 weight percent nickel-coated tungstencarbide particles having a particle size of −325 mesh, and between 0weight percent and about 15 weight percent crushed cemented chromiumcarbide-nickel particles having a particle size of −140+325 mesh. 17.The tough wear-resistant member of claim 1 wherein the matrix powdercomprises between about 80 weight percent and about crushed nickelcemented tungsten carbide particles having a particle size of −325 mesh,and between 0 weight percent and about 10 weight percent chromiumcarbide particles having a particle size of −45 mesh, between 0 weightpercent and about 25 weight percent nickel-coated tungsten carbideparticles having a particle size of −325 mesh, and between 0 weightpercent and about 15 weight percent crushed cemented chromiumcarbide-nickel particles having a particle size of −140+325 mesh. 18.The tough wear-resistant member of claim 1 wherein the matrix powdercomprises about 100 weight percent and about crushed nickel cementedtungsten carbide particles having a particle size of −325 mesh.
 19. Thetough wear-resistant member of claim 1 wherein the matrix powdercomprises about 95 weight percent and about 5 weight percent chromiumcarbide particles having a particle size of −45 mesh.
 20. The toughwear-resistant member of claim 1 wherein the matrix powder comprisesabout 80 weight percent crushed nickel cemented tungsten carbideparticles having a particle size of −325 mesh, and about 20 weightpercent nickel-coated tungsten carbide particles having a particle sizeof −325 mesh.
 21. The tough wear-resistant member of claim 1 wherein thematrix powder comprises about 90 weight percent crushed nickel cementedtungsten carbide particles having a particle size of −325 mesh, andabout 10 weight percent nickel-coated tungsten carbide particles havinga particle size of −325 mesh.
 22. The tough wear-resistant member ofclaim 1 wherein the matrix powder comprises about 85 weight percentcrushed nickel cemented tungsten carbide particles having a particlesize of −325 mesh, and about 15 weight percent nickel-coated tungstencarbide particles having a particle size of −325 mesh.
 23. A toughwear-resistant hard member comprising: a support having a surface area;a hard composite member affixed to the support over at least a portionof the surface area of the support; the hard composite member comprisinga plurality of discrete hard constituents distributed in the hardcomposite member, each one of the discrete hard constituents is of asize so as to have a surface area between about 0.001 square inches andabout 16 square inches; the discrete hard constituents comprise one ormore of cemented carbides and ceramics; sintered cemented tungstencarbide wherein a binder includes one or more of cobalt, nickel, ironand molybdenum, coated sintered cemented tungsten carbide wherein abinder includes one or more of cobalt, nickel, iron and molybdenum, andthe coating comprises one or more of nickel, cobalt, iron andmolybdenum, one or more of the carbides, nitrides, and borides of one ormore of titanium, niobium, tantalum, hafnium, and zirconium, tungstencarbide, one or more of the coated carbides, coated nitrides, and coatedborides of one or more of titanium, niobium, tantalum, hafnium, andzirconium wherein the coating comprises one or more of nickel, cobalt,iron and molybdenum; coated tungsten carbide wherein the coatingcomprises one or more of nickel, cobalt, iron and molybdenum, coatedsilicon carbide wherein the coating comprises one or more of nickel,cobalt, iron and molybdenum, and coated silicon nitride wherein thecoating comprises one or more of nickel, cobalt, iron and molybdenum;coated boron carbide, the hard composite member further comprising amatrix powder comprising hard particles wherein substantially all of thehard particles of the matrix powder have a smaller size than the hardconstituents; the hard composite member further comprising an infiltrantalloy having a melting point between about 500 degrees Centigrade andabout 1400 degrees Centigrade, and the infiltrant alloy beinginfiltrated under heat into a mixture of the discrete hard constituentsand the matrix powder so as to not effectively degrade the hardconstituents upon infiltration, whereby the hard constituents and thematrix powder and the infiltrant alloy are bonded together to form thehard composite member; and the support being made of a material that isbondable with the infiltrant alloy whereby the infiltrant alloy forms ajoint at the joinder of the support and the hard composite member. 24.The tough wear-resistant member of claim 23 wherein the infiltrant alloycomprises between about 15 weight percent and about 55 weight percentcopper, between about 1 weight percent and about 18 weight percentnickel, between about 5 weight percent and about 40 weight percent zinc,up to about 25 weight percent manganese, between about 15 weight percentand about 75 weight percent silver, and up to about 5 weight percenttin.
 25. The tough wear-resistant member of claim 24 wherein theinfiltrant alloy comprises about 53 weight percent copper, about 15weight percent nickel, about 8 weight percent zinc, and about 24 weightpercent manganese.
 26. The tough wear-resistant member of claim 24wherein the infiltrant alloy comprises about 45 weight percent copper,about 35 weight percent zinc, and about 20 weight percent silver. 27.The tough wear-resistant member of claim 24 wherein the infiltrant alloycomprises 40 weight percent copper, about 33 weight percent zinc, about25 weight percent silver, and about 2 weight percent tin.
 28. The toughwear-resistant member of claim 24 wherein the infiltrant alloy comprisesabout 42 weight percent copper, about 2 weight percent nickel, and about56 weight percent silver.
 29. The tough wear-resistant member of claim24 wherein the infiltrant alloy comprises about 20 weight percentcopper, about 10 weight percent zinc, and about 70 weight percentsilver.
 30. The tough wear-resistant member of claim 24 wherein theinfiltrant alloy comprises
 31. The tough wear-resistant member of claim24 wherein the infiltrant alloy has a melting point between about 600degrees Centigrade and about 800 degrees Centigrade.
 32. The toughwear-resistant member of claim 24 wherein the infiltrant alloy has amelting point between about 690 degrees Centigrade and about 770 degreesCentigrade.
 33. The tough wear-resistant member of claim 24 wherein theinfiltrant alloy has a melting point less than about 700 degreesCentigrade.
 34. The tough wear-resistant member of claim 23 wherein thehard constituents comprise sintered cobalt cemented tungsten carbidecompacts wherein the cobalt content is about 10 weight percent.
 35. Thetough wear-resistant member of claim 23 wherein the hard constituentscomprise sintered cobalt cemented tungsten carbide compacts wherein thecobalt content is about 6 weight percent.
 36. The tough wear-resistantmember of claim 23 wherein the hard constituents comprise nickel-coatedsintered cobalt cemented tungsten carbide compacts wherein the cobaltcontent is about 10 weight percent.
 37. A tough wear-resistant hardmember comprising: a hard composite member; a support having a surfacearea adjacent to the hard composite member; the hard composite memberaffixed to the support over at least a portion of the adjacent surfacearea of the support; the hard composite member comprising a plurality ofdiscrete hard constituents distributed in the hard composite member,each one of the discrete hard constituents is of a size so as to have asurface area between about 0.001 square inches and about 16 squareinches; the hard composite member further comprising a matrix powdercomprising hard particles wherein substantially all of the hardparticles have a size smaller than the size of the hard constituents;the hard composite member further comprising an infiltrant alloy havinga melting point between about 500 degrees Centigrade and about 1400degrees Centigrade, and the infiltrant alloy being infiltrated underheat into a mixture of the discrete hard constituents and the matrixpowder so as to not effectively degrade the hard constituents uponinfiltration, whereby the hard constituents and the matrix powder andthe infiltrant alloy are bonded together to form the hard compositemember; and the support being made of a material that is bondable withthe infiltrant alloy whereby the infiltrant alloy forms a joint at theinterface of the support and the hard composite member.
 38. The toughwear-resistant member of claim 37 wherein the hard composite beingaffixed to the support over substantially all of the adjacent surfacearea of the support.
 39. The tough wear-resistant member of claim 37wherein the portion of the adjacent surface area of the support to whichthe hard composite is affixed is roughened.
 40. The tough wear-resistantmember of claim 37 wherein the support contains at least one bore, andat least a portion of the hard composite being contained within thebore.
 41. The tough wear-resistant member of claim 37 wherein thesupport presenting a plurality of surface areas, and the hard compositebeing affixed to the support over substantially all of the plurality ofsurface areas.